Plug finishing system and tool therefor

Abstract

A plug finishing system involves forming a counterbore in a cover board above the head of a fastener as it is driven by a specially constructed driver. A plug, which is dimensioned for the counterbore and has a reduced portion, is inserted into the counterbore and positioned so that its exterior surface is co-planar with the exterior surface of the cover board.

1. A method of fastening a cover board to a support comprising:
 providing the cover board having a support face and an opposing exterior face; 
 providing a plurality of substantially identical plugs, said plugs and cover board having substantially the same material composition, said plugs having an upper enlarged cylindrical portion and a lower reduced cylindrical portion with a tapered transition portion between said upper enlarged cylindrical portion and said lower reduced cylindrical portion; 
 disposing the cover board on the support so that the support face is adjacent the support; 
 providing a plurality of fasteners each having a threaded shank extending from a head; 
 driving each fastener threaded shank through the cover board and partially into the support at a pre-established depth; 
 forming a cylindrical counterbore in the cover board above the head at the same time each fastener is being driven through the cover board; and 
 disposing a plug having a substantially planar exterior face in each counterbore so that the exterior face of said cover board and said exterior face of said plug are co-planar, and said upper enlarged cylindrical portion of said plug engages said counter bore and said lower reduced cylindrical portion is spaced from said counter bore to form an annular cavity. 
 
     
     
       2. The method of  claim 1  wherein the counterbore is formed by the fastener head as the fastener head is driven to a position intermediate the cover board exterior face and the cover board support face. 
     
     
       3. The method of  claim 1  further comprising the step of providing a driver, wherein the steps of driving the fastener and forming the counterbore are performed in the same operation while the driver is interengaged with the fastener head. 
     
     
       4. The method of  claim 1  wherein the cover board is selected from a deck or trim board comprised of material selected from the group consisting of natural wood, wood/plastic composite, polymer and cellular PVC. 
     
     
       5. The method of  claim 1  wherein the counterbore has a diameter that is less than a diameter of the fastener head. 
     
     
       6. A method of fastening a cover board to a support comprising:
 providing the cover board having a support face and an opposing exterior face; 
 disposing the cover board on the support so that the support face is adjacent the support; 
 providing a driver having a fastener bit and a fastener having a head; 
 interengaging the fastener bit to the fastener head; 
 rotating the driver; 
 driving the fastener head to a position intermediate the cover board exterior face and support face; 
 forming a cylindrical counterbore in the cover board exterior face while the fastener is interengaged with the fastener head; 
 providing a plurality of substantially identical plugs, said plugs and cover board having substantially the same material composition, said plugs having an upper enlarged cylindrical portion and a lower reduced cylindrical portion with a tapered transition portion between said upper enlarged transition portion and said upper enlarged cylindrical portion and said lower reduced cylindrical portion; and 
 disposing a plug having a substantially planar exterior face in the counterbore so that the exterior face of said board and the exterior face of said plug are substantially coplanar, and said upper enlarged cylindrical portion of said plug engages said counter bore and said lower reduced cylindrical portion is spaced from said counter bore to form an annular cavity. 
 
     
     
       7. The method of  claim 6  wherein the counterbore has a diameter that is less than a diameter of the fastener head. 
     
     
       8. The method of  claim 7  wherein the steps of driving the fastener head and forming the counterbore are performed in the same operation. 
     
     
       9. The method of  claim 8  wherein the counterbore is at least partially formed by the head of the fastener engaging the cover board. 
     
     
       10. The method of  claim 6  wherein the cover board is selected from a deck or trim board comprised of material selected from the group consisting of natural wood, wood/plastic composite, polymer and cellular PVC.